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Bicycles

Free Drive "bike-by-wire" system will soon be hitting the road

By Ben Coxworth
February 24, 2023
Free Drive "bike-by-wire" system will soon be hitting the road
Schaeffler's Free Drive system will make its commercial debut on the mocci ebike
Schaeffler's Free Drive system will make its commercial debut on the mocci ebike
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The Free Drive bottom bracket generator
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The Free Drive bottom bracket generator
Schaeffler's Free Drive system will make its commercial debut on the mocci ebike
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Schaeffler's Free Drive system will make its commercial debut on the mocci ebike
The mocci ebike, pictured here with its optional cargo trailer
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The mocci ebike, pictured here with its optional cargo trailer
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Two years ago we first heard about Schaeffler's Free Drive system, which uses a generator instead of a chain or belt to propel an ebike. The technology is now entering its first commercial use, in fleets of ebikes made for commuting and cargo-hauling.

Developed in partnership with two-wheel electric drive specialist Heinzmann, the Free Drive system incorporates a bottom-bracket-integrated generator, a rear hub motor, a lithium battery pack, and a handlebar-mounted control module.

As the rider pedals, they spin up the generator. Doing so converts their mechanical energy into electrical energy, which is fed into the motor. That motor converts the electrical energy back into mechanical energy, which is used to turn the wheel.

The generator regulates the amount of resistance that the rider experiences while pedaling, based on the level of pedaling effort they have selected in order to maintain cruising speed. Should they pedal harder than is necessary, the excess energy is stored in the battery. A regenerative braking system helps keep the battery topped up.

The Free Drive bottom bracket generator
The Free Drive bottom bracket generator

Although Schaeffler admits that Free Drive is about 5% less efficient than a chain drive at converting pedaling power into forward motion, the system also allows for much greater freedom when it comes to the design of pedal-powered vehicles – after all, the crankset only needs to be connected to the rear wheel via electrical wiring.

Additionally, Free Drive reportedly requires much less maintenance than a chain drive.

Schaeffler has now announced that the system will be making its first commercial appearance in the mocci Smart Pedal Vehicle made by fellow German company CIP Mobility. The latter firm will be selling fleets of the mocci ebikes to corporate clients, who will in turn use them in bike-sharing projects, urban deliveries or other applications.

The mocci ebike, pictured here with its optional cargo trailer
The mocci ebike, pictured here with its optional cargo trailer

Along with its Free Drive drivetrain, some of the mocci's other features include sturdy one-piece monocoque wheels; a recyclable polyamide frame made using a unique injection molding process; a built-in telemetry system; plus multiple rack-mounting points and an optional cargo trailer.

Sources: Schaeffler, CIP Group via Electrek

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12 comments
Ben Coxworth
Ben Coxworth
Based out of Edmonton, Canada, Ben Coxworth has been writing for New Atlas since 2009 and is presently Managing Editor for North America. An experienced freelance writer, he previously obtained an English BA from the University of Saskatchewan, then spent over 20 years working in various markets as a television reporter, producer and news videographer. Ben is particularly interested in scientific innovation, human-powered transportation, and the marine environment.

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12 comments
paul314
I guess this makes for a more consistent pedaling experience, which might be good. I'm not sure I want to be propelling a cargo bike *and* charging a battery at the same time. Wonder if they will ultimately make a motorized version of the trailer, either with its own battery or power from the bike.
TechGazer
The big question, for those not ridiculously rich, is how much it costs compared to chain&sprockets. For typical riding conditions, I think it will make little difference in how tired you feel after a long ride. For short rides, probably no difference at all. For situations where you need electric assist, how much extra are you paying for the ability to save maybe a few dollars a year in grid power cost by replacing that power with pedalling?
anthony88
If they can use some of that energy to keep the food in that delivery rider's many boxes cool/warm, then they'll be able to add another box in front of the handlebars and make him carry even more.
alan c
I can't imagine anyone buying a bike which is guaranteed less efficient than one with a chain, and how long does it take to lubricate a chain now and then?
Ligfietser
For the individual bicycle rider to adopt this system in any sort of bike depends imho almost totally in the ability of this set-up to emulate the feeling of real pedaling on a bike with a chain drive. If it is on cargobike and you are working for a company that uses these kind of bikes, then you just have to accept it. Hope that Schaeffler will be present at the SPEZI 2023 in Lauchringen, Germany (29 & 30 April 2023).
LooseSends
Undoubtedly an outrageously expensive trade-off which is likely why these are targeted at inter-city deliveries. The 5% tradeoff is no big deal for this application given the bonus of lowered mechanical maintenance.

However, despite having a battery to smooth out the effort, I wonder what happens when you're so lazy as to do the absolute minimum amount of pedaling, and find yourself half way up a steep hill without sufficient stored energy to make it further?
tokyotea
They've stolen the design of the 1929 Ascot-Pullin motorcycle.
Martin Hone
I would like to know more details on the mocci's other features, such as the one-piece monocoque wheels; a recyclable polyamide frame made using a unique injection molding process;
Jezzafool
What about the weight difference between a generator and chain drive? It sounds heavy.
freddotu
@alan c, I'm willing to bet that there's a much greater efficiency difference than five percent. A clean well lubricated chain is unparalleled for energy transfer, especially considering the weight difference. I suppose marketing came up with the idea to state that there is a difference, but then to understate it for better sales.
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